Hi Marv, yeah that's a pretty advanced type of shape. Probably the biggest problem with your current approach is trying to model it in a "patch by patch" type approach. It will probably be less awkward to build some of the shapes if you build some pieces as extended surfaces that are then cut off where they intersect, rather than trying to directly construct surfaces that try to follow those final boundaries directly...

See here for an example:
http://moi3d.com/forum/index.php?webtag=MOI&msg=4824.10

Right now the sweep is getting all bunched up because it's getting too much pressure on it by having it try to turn in a small area.

If you try to make something follow a curved path and the offset from the path is larger than the radius of the bend you'll get bunching like this:




That's why your sweep looks sort of weird and squiggly because in the lower area it's getting this same kind of bunching where it is crossing back over top of itself.

- Michael